DMG MORI will present its latest CNC technologies and most recent developments in the U.S. market. It will feature a total of over 25 machine tools in an exhibition area of 17,000 sq. ft. The portfolio includes U.S. premieres, the ULTRASONIC 20 linear and the SPRINT 32|8, as well as the locally produced DMU 50 with PH 150 and NHX 4000 2nd Generation with RPP. DMG MORI will focus on local production in Davis, CA, and on the established direct sales business model in the U.S. market. Technology Cycles, Automation Solutions, Industry 4.0 and additive manufacturing (AM) are further highlights to be presented by DMG MORI.

With a production capacity of up to 100 machines per month, the Davis location manufactures and assembles horizontal machining centers (HMCs), 5-axis universal milling machines, vertical mills and turning centers. "Design and production activities in California provide price-competitive, customized technical solutions to demanding production problems," said a company spokesperson.

At IMTS, customers will experience live demonstrations on locally manufactured machines and take a virtual tour through the factory in Davis. They will discover how DMG MORI builds its machines, from design to production.

Industry 4.0 with CELOS

"DMG MORI is pushing forward intelligent software solutions as the elementary basis of the digital transformation of manufacturing process chains," said the spokesperson. "In the age of Industry 4.0, it is very important to build up a customer-oriented strategy of digital manufacturing. As a part of this strategy, DMG MORI supports customers on the way to digital transformation by offering the app-based CELOS system and DMG MORI Technology Cycles."

With its open architecture, CELOS allows the exchange of information with higher-level structures in addition to its effects in the shop floor area. As a result, CELOS offers customers complete integration of their machines in the company organization. "The benefits in day-to-day operation include a 30% time saving in tooling times, 50% less time and effort for the calculation of technology values, and the search for important information, among others," said the spokesperson. "In addition, CELOS offers smooth entry into the future of metalcutting production, because this takes place gradually. Customers using CELOS today receive, first, unlimited access to the existing 16 CELOS APPs and second, the chance to benefit from future apps, as CELOS is, and will remain, upwardly compatible."

DMG MORI currently has 24 exclusive DMG MORI Technology Cycles for the fields of turning / turning-milling or milling / milling-turning in its portfolio. These are designed to enable the operator in the workshop to program complex machining up to 60% faster directly on the machine via a dialog using parameterized context menus.

Additive Manufacturing of 3-D Components

The combination of laser deposition welding using a powder nozzle and machining opens up new perspectives in AM. DMG MORI offers two hybrid machines, the LASERTEC 65 3D and the LASERTEC 4300 3D.

DMG MORI uses a blown powder deposition welding process with laser, a process that has long been used for repair work in the tool making and turbine technology branches. In this process the powder is melted onto the base material by the laser beam. DMG MORI builds up layer by layer, but only uses the powder where it is actually needed. This significantly reduces the necessary quantity of powder. Another key advantage is the around 10x faster build-up of the material. The hybrid machine allows the integral combination of additive and subtractive manufacturing in a single set-up.

The basic machine of the LASERTEC 65 3D is a DMU 65 monoBLOCK 5-axis machine for high-precision milling operations with up to 5-axis simultaneous machining. The integrated laser head is equipped with a 2.5 kW diode laser. It is automatically exchangeable, and during milling operations it is moved completely out of the working room of the machine. The machine is suited for the complete hybrid production of components as well as for repair work and the application of partial or full coatings. This year, DMG MORI has expanded the AM program with the LASERTEC 4300 3D. This second hybrid machine will add the possibility of turning operations to laser deposition welding and 5-axis milling, so that rotation-symmetric components can now also be produced with the hybrid process. Equipped with a mirrored C-axis, workpieces can also be machined on the rear side with the counter-spindle, thus enabling 6-sided complete machining of the finished part.

U.S. Premiere: SPRINT 32|8

DMG MORI has expanded its series of automatic lathes equipped with a SWISSTYPEkit to include the SPRINT 32|5 and SPRINT 32|8 for bar material with diameters of up to 1.3". The SWISSTYPEkit allows for the machining of both short and long components.

Following in the footsteps of the smaller SPRINT 20|5, the SPRINT 32|5 and SPRINT 32|8 are versatile automatic lathes. They feature a footprint of 30.1 sq. ft. and offer a large work area for workpieces of up to o1.3" x 23.6". The two new SPRINT models feature the SWISSTYPEkit, which enables both short and long turning on one machine with set-up times of less than 30 minutes. To achieve this, the spindle stroke is lengthened from 4" to 10". An optional quick tool-change system reduces set-up times by another 20%.

The SPRINT 32|8 is suited to the machining of complex workpieces. It has an additional Y-axis for the second tool carrier plus a C-axis for the counter-spindle. The SPRINT 32|8 is equipped with a total of six linear axes and two C-axes and has 28 tool pockets. This expansion option of the machine has a third independent tool carrier that is suitable for deep hole drilling on the main spindle, for example, and that also enables 4-axis machining on the main spindle. These two stations can also be equipped optionally for powered tools. The second tool carrier has eight pockets for rear-side machining, four of which are equipped for powered tools. There are pockets for a total of 10 (eight in the standard version) powered tools.

U.S. Premiere: ULTRASONIC 20 linear 2nd Generation

The new ULTRASONIC 20 linear 2nd Generation features extensive optimizations, from the expanded ULTRASONIC technology and machine construction to the performance and available options. Spindle speeds of optionally up to 60,000 RPM, more powerful drive motors, a smaller footprint plus CELOS with apps developed specifically for ULTRASONIC are among the innovations suited to the optical, clock and watch, medical and high-precision mold construction sectors.

The ULTRASONIC 20 linear 2nd Generation includes a new, completely digitally controlled ultrasonic generator plus ULTRASONIC actuators with enhanced performance. The toolholders with adapted actuator technology are changed into the milling spindle automatically. Each of these holders contains piezo elements, which are activated by a program-controlled inductive system with a high frequency of between 20 and 50 kHz. The actual tool rotation is thus superimposed with an additional tool movement in the longitudinal direction so that a defined amplitude, which can be programed in the NC program, in the range of up to more than 10 µ is generated on the cutting edge of the tool or on the grinding layer. During grinding, drilling and milling this ULTRASONIC superimposition of vibrations has a direct, positive impact on process forces, metal removal performance and tool service life for greater cost efficiency and accuracy.

"ULTRASONIC results in a higher removal rate, accurate edge machining and up to 40% reduced process forces in the machining of advanced materials," said the spokesperson. "Deflections are minimized while workpiece accuracy and process reliability are increased. In addition, this oscillating contact interruption results in better lubrication and cooling of the cutting edge as well as optimum removal of particles from the active zone. This enables longer tool service life as well as excellent surface qualities of up to Ra <0.1 µ for hard, brittle high-performance materials such as glass, ceramics and corundum, as well as other materials that are difficult to machine such as hard metal or fiber composites. The ULTRASONIC 20 linear 2nd Generation thus uniquely combines high speed cutting and highly efficient ULTRASONIC grinding of advanced materials on one machine."

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